Coil for a compressor which can be electrically driven, and corresponding production method

Abstract

A method for producing a coil of a compressor (1) which can be electrically driven, a coil which is produced in accordance with this method, and a stator and a compressor which can be electrically driven. The production process for the coil includes the steps of: producing (100) a first winding (101) of the coil (12), producing (200) a second winding (102) of the coil (12), and compacting (300) the first winding (101) and the second winding (102) by virtue of an external action of force. A cross-sectional area (111, 112, 111′, 112′) of a wire of the first winding (101) and of the second winding (102) is deformed.

The invention claimed is: 
     
       1. A method for producing a compressor ( 1 ) including an electric drive motor ( 7 ) having a stator with a coil ( 12 ) and having a rotor, said electric drive motor ( 7 ) having a predefined air gap between the stator and the rotor, the method comprising the steps of:
 producing (S 100 ) a first winding ( 101 ) of the coil ( 12 ) from multiple loops of wire ( 111 ,  111 ′), 
 producing (S 200 ) a second winding ( 102 ) of the coil ( 12 ) from multiple loops of wire ( 121 ,  121 ′), 
 compacting (S 300 ) the first winding ( 101 ) and the second winding ( 102 ) by virtue of an external action of force, wherein a cross-sectional area of a wire ( 111 ,  111 ′) of the first winding ( 101 ) and a cross-sectional area of a wire ( 121 ,  121 ′) of the second winding ( 102 ) is deformed; 
 wherein, for said compacting (S 300 ) in a first direction, the windings ( 101 ,  102 ) of the coil ( 12 ) are arranged between substantially parallel surfaces ( 106 ,  107 ) of first and second tool parts ( 104 ,  105 ), wherein the surfaces ( 106 ,  107 ) of the tool parts ( 104 ,  105 ) have a curvature which serves to match the coil ( 12 ) to the predefined air gap between the stator and the rotor of the electric drive motor ( 7 ), and wherein compacting in the first direction occurs when the first tool part ( 104 ) is moved towards the second tool part ( 105 ), 
 wherein the tool parts have first and second linear extension surfaces at the ends of the surfaces which have a curvature, 
 wherein the windings ( 101 ,  102 ) of the coil ( 12 ) are compacted by a first die ( 108 ) moving in a second direction (P a ) parallel to the first linear extension surfaces of the two tool parts ( 104 ,  105 ), 
 wherein the windings ( 101 ,  102 ) of the coil ( 12 ) are compacted by a second die ( 109 ) in a third direction (P b ) parallel to the second linear extension surfaces of the two tool parts ( 104 ,  105 ), 
 whereby the compacted windings ( 101 ,  102 ) have a surface corresponding to the air gap between stator and rotor. 
 
     
     
       2. The method as claimed in  claim 1 , wherein, in a first step, the first winding ( 101 ) is compacted together with a first multiplicity of windings, and, in a second step, the second winding ( 102 ) is compacted together with a second multiplicity of windings to form a coil ( 12 ). 
     
     
       3. The method as claimed in  claim 2 , wherein volume of the coil ( 12 ) is reduced by 5% to 30%. 
     
     
       4. The method as claimed in  claim 2 , wherein volume of the coil ( 12 ) is reduced by 10% to 20%. 
     
     
       5. The method as claimed in  claim 1 , wherein the coil is compacted in a magnetically active section (I, II, III, IV), and wherein a winding head ( 25   a ,  25   b ) of the coil is also compacted, after all of the windings ( 101 ,  102 ) of the coil are produced. 
     
     
       6. A coil for an electrically driven compressor ( 1 ) obtained by the method as claimed in  claim 1 . 
     
     
       7. A stator for an electrical drive of a compressor ( 1 ), comprising a coil as claimed in  claim 6 . 
     
     
       8. The stator as claimed in  claim 7 , comprising three coils which are arranged in a delta circuit by adjacent electrical connections of two coils being combined in each case for the purpose of allowing an external electrical connection to make contact with said electrical connections. 
     
     
       9. The stator as claimed in  claim 7 , the coils of said stator being fixed relative to one another by means of a cured fluid. 
     
     
       10. A compressor ( 1 ) for an internal combustion engine, which compressor can be electrically driven and comprises an electrical drive having a stator as claimed in  claim 7 . 
     
     
       11. The stator as claimed in  claim 7 , the coils of said stator being fixed relative to one another by means of a cured insulating enamel or adhesive. 
     
     
       12. The method as claimed in  claim 1 , wherein each wire comprises a plurality of copper strands encased in insulation. 
     
     
       13. The method as claimed in  claim 1 , wherein the second winding is compacted subsequent to the first winding. 
     
     
       14. The method as claimed in  claim 1 , wherein the first and second windings are compacted together. 
     
     
       15. The method as claimed in  claim 1 , wherein, in a first step, a first multiplicity of windings is compacted together, and, in a second step, a second multiplicity of windings is compacted together to form a coil. 
     
     
       16. The method as claimed in  claim 1 , wherein the curvature of the surfaces ( 106 ,  107 ) of the tool parts ( 104 ,  105 ) extends over 90°. 
     
     
       17. The method as claimed in  claim 1 , wherein the curvature of the surfaces ( 106 ,  107 ) of the tool parts ( 104 ,  105 ) extends over 120°. 
     
     
       18. The method as claimed in  claim 1 , wherein the curvature of the surfaces ( 106 ,  107 ) of the tool parts ( 104 ,  105 ) extends over 180°.